Machining of Critical Aerospace Components: Challenges and Case Studies

The aerospace industry in Italy is an increasingly important contributor to economy, with a highly skilled workforce and the presence of companies operating globally. Machining processes constitute a fundamental part of the manufacturing supply chain, with a global market size exceeding 22 billion euros in 2020. However, evolving industry demands for components with increasingly stringent requirements necessitate optimized and reconfigurable machining processes. This White Paper investigates advanced methodologies for optimizing chip removal processes in the manufacturing of aerospace components and outlines key challenges and potential solutions through case studies, aiming to provide practical insights for industrial players. The paper focuses on critical components such as mirrors, aeroengine airfoils, and aerospace structures addressing issues like deflection/deformation, vibrations and surface quality/ integrity.